Unloader for discharging dry materials from bulk bags

ABSTRACT

An unloader for discharging and feeding dry, granular type materials from bulk bags. Among the many improvements of the discharge apparatus is an open frame ( 20 ) and offset discharge location. Other improvements include an I-beam ( 23 ) and frame design that keeps the hoist ( 25 ) movement within the four corner posts of the frame. The unloader may be provided with vibrators, vibration isolators, load cells, actuators ( 107, 108 ), massage paddles, or plates ( 106, 109 ) to assist in the discharge function.

BACKGROUND

1. Field of Invention

This invention relates to unloaders for discharging dry and semi-drymaterials from bulk bags.

2. Description of Related Art

As many processors improve their operations by using bulk bags, insteadof handling and manually dumping 50 lbs. and 100 lbs. paper bags, theneed for a safer, more compact and flexible frame design of bulk bagunloaders has grown.

One of the more vexing problems in handling bulk bags is the requirementof a tall, four-posted frame with a cantilevered I-Beam that extendsoutward at the top of the frame so that a bulk bag can be lifted fromits pallet on the floor up and onto the discharge apparatus of theunloader frame. The typical unloader frame is generally equipped withseveral diagonal and horizontal bracing structures between the fourvertical, corner posts and hoist apparatus. This extra bracing aroundthe frame makes it difficult to interface other types of feeding, dustcollection and discharge equipment close to the discharge spout locationof the bulk bag. Other problems and hazards are created when lifting aheavy bulk bag with the extended I-Beam configuration.

SUMMARY

It is the object of the invention to use a smaller footprint for a bulkbag unloader.

Another object of the invention is lift and discharge a bulk bag on astandard sized unloader frame without the use of a cantilevered I-Beam.Another object of the invention is to provide a safer method of liftinga bulk bag for unloading.

Yet another object of the invention is to provide a more open andaccessible frame around the bulk bag when it placed on the unloader.

Another object of the invention is to use a pick-up location anddischarge location within the area of a four-posted unloader frame.

Another object of the invention is to allow other types of conveying,dust collection and metering devices to be interfaced with the unloaderframe closer to the discharge spout of the bulk bag.

Yet another object of the invention is to eliminate the use of secondarybracing structures on the unloading frame.

Another object of the invention is to provide greater flexibility towhere the horizontal frames may be located on the four-vertical posts.

DRAWINGS

FIG. 1 is a side view of a bulk bag unloader with one bag positioned fordischarge while a second bag is staged on the floor waiting to be liftedinto position and discharged.

FIG. 2 is a side view of a bulk bag unloader frame with the hoist inposition to lift a full bulk bag from its pallet on the floor to thedischarge position.

FIG. 3 is a front view of a bulk bag lowered over the base ram and traysupport for discharging.

FIG. 4 is a top of a bulk bag unloader with an open side and offsetdischarge location.

FIG. 5 is a side view of a bulk bag unloader showing details of the bagsupport means.

FIG. 6 is a side view of an unloader bag support hopper having massagepaddles.

FIG. 7 is a top view of the hopper of FIG. 6.

FIG. 8 is a side view of the hopper shown in FIG. 6 with a bag startingto be unloaded.

FIG. 9 is a side view of the hopper and bag shown in FIG. 8 with the bagunloaded.

FIG. 10 is a top view of the mounting base showing a bottom actuatormanifold and pressure regulator.

FIG. 11 is an end view of an unloader of a bag lifted over a hopper fordischarge, and the vertical centers of gravity of the bags being insidethe frame.

FIG. 12 is a front view of an unloader having a plurality of platformhoppers.

DESCRIPTION

FIG. 1 is a side view of unloader frame 20. Top frame support 21 isequipped with corner brackets 21× and 21 y (21 v and 21 z not shown) andbottom frame 21 a is equipped with corner brackets 21 ax and 21 ay (21av and 21 az not shown) to secure corner posts 22 a and 22 b (22 c and22 d not shown) in position to form unloader frame 20. Unlike other bulkbag unloaders, I-beam 23 does not extend outside of the perimeter ofcorner posts 22 a, 22 b, 22 c and 22 d. I-beam 23 is secured to topframe 21 and allows hoist 25 to move between posts 22 a and 22 b viatrolley 24. Bag 29 a is held in position by bag support frame 28 and bagsupport tray 85. Bag support tray 85 may be located off center withinthe four corner posts 22 a, 22 b, 22 c and 22 d. Bag 29 b is on pallet84 in a location within the four corner posts 22 a, 22 b, 22 c and 22 dso that it can be lifted with hoist 25 when moved to the left end ofI-beam 23. Corner brackets 2 lay, 21 ax, 21 av and 21 az of bottom frame21 a are designed to provide lateral support and can be located anywhere along the corner posts 22 a, 22 b, 22 c and 22 d to allow for theheight of bag support tray 85 to be adjustable. Corner brackets 21 x, 21v, 21 y and 21 z also add lateral support and rigidity to unloader frame20 and may also be secured at any elevation.

FIG. 2 is a side view of unloader frame 20 with hoist 25 moved alongI-beam 23 via trolley 24 to a position over bag 29 b. Chain 26 and bagframe 28 are lowered for bag to be lifted. Bag 29 b is staged in theopen frame area of unloader 20 on floor 50. Bag support tray 85 isempty, ready for bag 29 b to be positioned thereon.

FIG. 3 is a front view of unloader frame 20 with bag 29 b lowered ontoram base 35 and bag support frame 85. Bottom frame 21 a does not have asupport member located between vertical posts 22 a and 22 d to providean open area directly under I-beam 23, trolley 24 and hoist 25.

FIG. 4 is a top view of bottom frame 21 a secured to vertical posts 22a, 22 b, 22 c and 22 d. Bag support tray is supported by cross beamsupports 86 a and 86 b. Pallet 84 is shown on floor in an open area ofunloader frame 20. Because a cross support brace is not used betweenvertical posts 22 a and 22 d of bottom frame 21 a and the bag supporttray 85 is located off center of unloader frame 20, the I-Beam and HoistAssembly (not shown) do not have to extend beyond vertical posts 22 a,22 b, 22 c and 22 d.

FIG. 5 is an end view of the lower section of the unloader with seathousing 95 secured to vertical support post 22 a. Axle 97 of seat frame96 is placed inside seat housing 95 to allow seat frame 96 to swivel offsupport post 22 a. Seat extension support 99, with seat 100 attached, ismounted to seat frame 96 at pivot joint 98. Seat 100 may be mounted in astationary position or in a swivel and foldable configuration as shown,to assist operator with the set up and discharge of a bulk bag on theunloader. It is understood that any configuration of the unloader may beprovided with a seat 100, and not just the configuration shown in FIG.5.

To provide the unloader with a variety of discharge options to handledifferent sized bags and/or materials with varying flow characteristics,bag support hopper 87 is equipped with hopper brackets 88 a and 88 b (88c and 88 d not shown) that may be supported by unloader frame brackets89 a and 89 b (89 c and 89 d not shown) on horizontal support frames 21a and 21 b (21 c and 21 d not shown). Bag support hopper 87 may beprovided as a rectangular or conical shape with various slope angles.Spacers 90 a and 90 b (90 c and 90 d not shown) are positioned betweenhopper brackets 88 a and 88 b (88 c and 88 d not shown) and unloaderframe brackets 89 a and 89 b (89 c and 89 d not shown). Spacers 90 a and90 b (90 c and 90 d not shown) may be interchanged with vibrationisolators, load cells or other discharge devices as the configurationdictates. It is intended that the vibration isolators, load cells, andother discharge devices fit in the same space as the spacers as shown inFIG. 5 to facilitate manufacture and/or reconfiguration of the unloader.Spacers 90 may be supplied in one or more units as required to supportbag support hopper 87. If vibration is desired to assist in breaking upsettled material inside the bulk bag, a vibrator may be secured tovibration flange 91 and vibration isolators used instead of spacers 90.Hopper flange ring 92 on bag support hopper 87 is equipped withaccessory mounting flange 92 a. Discharge device 94, such as iris valvewhich is attached discharge device plate 93 may be fastened togetherusing bolts, welds or with a V-band type clamp. Discharge device 94 mayinclude valves, surge hoppers, filters, conveyors and the like.

FIG. 6 is a side view a bag support hopper with mounting base 101 thatmay be secured to unloader frame brackets 89 a, 89 b, 89 c and 89 d (notshown) of unloader 20 (not shown.) To provide agitation to materialsshipped in bulk bags, unloaders are often equipped with plunger devicesand stretching mechanisms to empty bulk bags. These devices oftenrequire several feet of elevation space for mounting and operation.Mounting base 101 is equipped with pivoting massage paddles 104 a and104 b to form a platform for bulk bags to be placed upon for unloading.When lower group of bottom actuators 107 a and 107 b; and upper group oftop actuators 108 a and 108 b are deflated and at rest, massage paddles104 a and 104 b form a shallow hopper surface of approximately 15degrees with an elevation height of only about 30 cm (12 inches). Hopperflange ring 92 is attached to mounting 101 and may use an internalhopper ring 102 inside to direct the flow of material from a bulk bag(not shown) through a smaller valve or outlet opening of accessorymounting flange 92 a. Internal hopper ring 102 may have a vibrator (notshown) secured to it to help promote the flow of material from a bag.Top hinge ring plate 103 is secured to hopper flange ring 92 andmounting base 101 to provide support for hinges 105 a, 105 c, 105 d, 105e and 105 b. Massage paddle assemblies that attached to hinges 105 c,105 d and 105 e are not shown. Sandwiched between the top actuators 108a and 108 b and bottom actuators 107 a and 107 b are hinge plates 106 aand 106 b respectively. Massage paddles 104 a and 104 b; and hingesplates 106 a and 106 b incline and pivot inward using hinges 105 a and105 b when bottom actuators 107 a and 107 b and or 108 a and 108 b areinflated with compressed air. As bottom actuators 107 a and 107 b and/ortop actuators 108 a and 108 b are inflated, the angle of massage paddles104 a and 104 b is increased to help dispense material in bag.

Bottom restraints 110 a and 110 b are secured to mounting base 101 andhinge plates 106 a and 106 b to limit movement of actuators 107 a and107 b. Actuators 107 a, 107 b, 108 a and 108 b may rupture or becomedamaged if their movement is not limited by some type of mechanicallinkage or stopping device. Bottom and top restraints 110 a, 110 b, 111a and 111 b may be made of cable, chain or other types of linkagecomponents. To provide a protective guard over and around the movingparts of adjustable bag hopper 114 assembly, including massage paddles104 a and 104 b, hinge plates 106 a and 106 b and actuators 107 a, 107b, 108 a and 108 b, flexible cover 112 is secured to the perimeter ofmounting frame 101 at side joints 113 a and 113 b and over massagepaddles 104 a and 104 b via top plates 109 a and 109 b.

FIG. 7 is a top view of adjustable bag hopper 114 with base mountingframe 101 having top hinge ring plate 103 with hinges 105 a, 105 b, 105c, 105 d, 105 e, 105 f, 105 g and 105 h secured to it. Massage paddles104 a, 104 b, 104 c, 104 d, 104 e, 104 f, 104 g and 104 h; and hingeplates 106 a, 106 b, 106 c, 106 d, 106 e, 106 f, 106 g and 106 h aresecured to hinges 105 a, 105 b, 105 c, 105 d, 105 e, 105 f, 105 g and105 h respectively.

To move the top surface of massage paddles 104 a, 104 b, 104 c, 104 d,104 e, 104 f, 104 g and 104 h from an angle of approximately 15 to 30degrees to a maximum angle of approximately 70 to 85 degrees to helpagitate and empty the contents of a bulk bag (not shown), bottomactuators 107 a, 107 b, 107 c, 107 d, 107 e, 107 f, 107 g and 107 h aresecured to mounting base 101 and hinge plates 106 a, 106 b, 106 c, 106d, 106 e, 106 f, 106 g and 106 h together with top actuators 108 a, 108b, 108 c, 108 d, 108 e, 108 f, 108 g, and 108 h secured to hinge plates106 a, 106 b, 106 c, 106 d, 106 e, 106 f, 106 g and 106 h to massagepaddles 104 a, 104 b, 104 c, 104 d, 104 e, 104 f, 104 g and 104 hrespectively. Massage liner plates 109 a, 109 b, 109 c, 109 d, 109 f,109 g and 109 h may be used to hold flexible cover 112 massage paddles104 a, 104 b, 104 c, 104 d, 104 e, 104 f, 104 g and 104 h respectivelyif flexible cover 112 (not shown) is used with adjustable bag hopper114. Cover ring 115 (not shown) is placed on top of flexible cover 112and top hinge ring plate 103 around opening 116 to hold the edge offlexible cover 112 in place. Because many bulk bags are rectangular inshape and therefore materials does not always empty out of its cornerseven when stretched or otherwise massaged, corner massage paddles 104 c,104 e, 104 h and 104 f are very effective in emptying bulk bag becausethey incline to a steep angle of about 80 to 90 degrees and pushdirectly against the corners of a bag. In addition to corner massagepaddles 104 c, 104 e, 104 h and 104 f, side massage paddles 104 d, 104b, 104 g and 104 a also incline to an angle of about 80 to 90 degrees toform a very steep sided hopper, capable of discharging almost all typesof materials that are handled in bulk bags.

FIG. 8 is a side view of bulk bag 29 b placed on adjustable bag hopper114 with bottom actuators 107 a and 107 b inflated to raise massagepaddles 104 a and 104 b respectively to an angle of about 45 degrees.Actuators 107 a and 107 b may be inflated one or more times to break upand loosen material 29 c in bag 29 b for agitation purposes.

FIG. 9 is a side view of adjustable bag hopper 114 with bottom actuators107 a and 107 b; and top actuators 108 a and 108 b fully inflated toraise massage paddles 104 a and 104 b to an angle of approximately 80 to90 degrees to provide complete emptying of bag 29 b. Internal hopperring may be used with hopper flange ring 92 with vibrator 116 to aid inmaterial discharge of a bulk bag. Because the adjustable bag hopper 114can perform the complete discharge function for emptying bulk bags,which includes the agitation and massage function to break up caked andcompacted materials; and also the ability to completely empty a bagwithout stretching it, adjustable bag hopper 114 may be mounted onportable unloaders, mixers and other types of vessels and equipment thatbulk bags may be emptied from for applications that have in restrictedhead room areas and other space constraints.

FIG. 10 is a top view of mounting base 101 with bottom actuator manifold117 a and bottom pressure regulator 118 a assembly that supplies air tobottom actuators 107 a, 107 b, 107 c, 107 d, 107 e, 107 f, 107 g and 107h through air lines 120 a, 120 b, 120 c, 120 d, 120 e, 120 f, 120 g and120 h respectively. Top actuator manifold 117 b and top pressureregulator 118 b may supply air to top actuators 108 a, 108 b, 108 c, 108d, 108 e, 108 f, 108 g and 108 h through air lines 119 a, 119 b, 119 c,119 d, 119 e, 119 f, 119 g and 119 h respectively. Valves 121 (notshown) may control air-flow from compressors or other air sources toactuator manifolds 117 a and 117 b and pressure regulators 118 a and 118b on a manual or automatic basis. Valves may be controlled by a PLC andor adjusted manually according to a particular discharge process.

FIG. 11 is an end view of unloader 20 with bag 29 j lifted over bagplatform hopper 85 j for discharge. Bag 29 f on pallet 84 is placedbetween front posts 22 a and 22 d (not shown) of unloader 20 so that itis ready for placement on bag platform hopper 85 j once bag 29 j isemptied. The footprint of unloader 20 and bag 29 f is typically smallerthan the footprint of a cantilevered unloader (not shown) because thebag staged 29 f is inside frame post 22 a and 22 d (not shown) ofunloader 20. Because bag platform hopper 85 j is off center andpositioned towards the back of unloader also allows for a smallerfootprint than conventional, cantilevered I-Beam unloaders.

FIG. 12 is a front view of unloader 20 having multiple bag platformhoppers 85 h, 85 i and 85 j. A single unloader 20 frame can be used tounload bags 29 h, 29 i and 29 j on bag platform hoppers 85 h, 85 i and85 j respectively because the frame design does not require I-beam's 23h, 23 i and 23 j to be cantilevered. Also, because I-Beam's 23 h, 23 iand 23 j are not cantilevered, unloader frame 20 does not require crossbracing supports as conventional cantilevered frames. Unloader 20provides a single frame for multiple bag discharge locations that allowscosts to be lower and smaller space requirements.

While there have been described what are at present considered to be thepreferred embodiments of this invention, it will be obvious to thoseskilled in the art that various changes and modifications may be madetherein without departing from the invention, and it is, therefore,aimed to cover all such changes and modifications as fall within thetrue spirit and scope of the invention.

1. A bulk bag unloader comprising an adjustable frame constructedwithout cross bracing, a bottom frame secured to the adjustable frame, aram base removably secured to the bottom frame, a bag tray adapted tosupport a bulk bag removably secured to the ram base, a top framesecured to the adjustable frame, an I-beam secured to the top frame,said I-beam being substantially the same length as the adjustable frameis wide, a trolley adapted to traverse the I-beam, and a hoist securedto the trolley.
 2. The unloader of claim 1, further comprising a seatmounted to the unloader.
 3. A bulk bag unloader comprising at least onehorizontal frame support, unloader frame brackets secured to the framesupports, and a bag support hopper supported by the unloader brackets.4. The unloader of claim 3, said hopper comprising hopper bracketsadapted to support the hopper by the unloader frame brackets.
 5. Theunloader of claim 4, further comprising at least one spacer disposed thehopper brackets and unloader frame brackets.
 6. The unloader of claim 4,further comprising at least one load cell disposed the hopper bracketsand unloader frame brackets.
 7. The unloader of claim 4, furthercomprising at least one vibration isolator disposed the hopper bracketsand unloader frame brackets.
 8. The unloader of claim 7, furthercomprising a vibration flange secured to the hopper.
 9. The unloader ofclaim 3, further comprising a hopper flange ring secured to said hopper.10. The unloader of claim 9, further comprising a discharge device platesecured to said hopper flange ring.
 11. The unloader of claim 10,further comprising a discharge device removably secured to saiddischarge device plate.
 12. The unloader of claim 11, wherein saiddischarge device is one taken from the group comprising a valve, surgehopper, filter, and conveyor.
 13. The unloader of claim 3, furthercomprising a swiveled seat mounted to an unloader adjustable frame. 14.A bulk bag unloader comprising at least one horizontal frame support, aplurality of unloader frame brackets secured to the frame supports, abag support hopper supported by the unloader brackets, and a seatmounted to the unloader.
 15. A bulk bag unloader comprising a frameadapted to support a loaded bulk bag, the frame defining a boundarybetween inside of the frame and outside of the frame; and an I-beam forsupporting the loaded bulk bag, the I-beam secured to the top of theframe and being completely contained inside of the frame.
 16. Theunloader of claim 15, further comprising a bag tray adapted to support abulk bag and secured in a spaced, off-center relationship to the frame.17. The unloader of claim 16, wherein the frame is sized such that thevertical centers of gravity of two horizontally adjacent bulk bags canbe inside the frame.
 18. A bulk bag unloader comprising a frame adaptedto support a loaded bulk bag, the frame defining a boundary betweeninside of the frame and outside of the frame; and an I-beam forsupported the loaded bulk bag secured to the top frame, the unloadersuitably adapted to support a second bulk bag such that at least aportion of the second bulk bag can be inside the frame.
 19. A bulk bagunloader comprising a bag support hopper, the hopper comprising ahorizontal mounting base, a plurality of hinge plates hingedly securedto the mounting base, and a plurality of top plates hingedly secured tothe mounting base or the hinge plates.
 20. The unloader of claim 19,further comprising a plurality of bottom actuators disposed between themounting base and the hinge plates, adapted to increase the angle of thehinge plates relative to the mounting base when the bottom actuators areinflated.
 21. The unloader of claim 20, further comprising a pluralityof top actuators disposed between the hinge plates and the top plates,adapted to increase the angle of the top plates relative to the hingeplates when the top actuators are inflated.
 22. The unloader of claim 21wherein the hinge plates, top plates, and mounting base form a rigidhopper for the bag when the top actuators and bottom actuators areinflated.
 23. The unloader of claim 19, further comprising a flexiblecover secured from around the outside perimeter of the mounting base tothe top plates, adapted to protect operators from moving parts of theunloader.
 24. A bulk bag unloader comprising a seat adapted to assist anoperator in unloading a bulk bag while on a bulk bag unloader.